AtulFegade BBA&BBM(IB)

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Thestepbystepconversionofoneformofmaterial y f f f intoanotherformthroughchemicalormechanical processtocreateorenhancetheutilityoftheproduct totheuser. totheuser Productionmanagementdealswithdecision makingrelatedtoproductionprocessessothatthe resultinggoodsorservicesareproducedaccordingto specifications,intheamountandbytheschedule demandedandoutofminimumcost.E.S.Buffa d d d d f ff

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1776Specializationoflabour inmanufacturingAdam Smith h 1799Interchangeableparts,costaccountingEli Whitneyandothers 1832Divisionoflabour byskill;assignmentofjobsby skill;basicsoftimestudyCharlesBabbage 1900Scientificmanagementtimestudyandwork study developed;dividingplanninganddoingofwork FrederickW.Taylor 1900MotionofstudyofjobsFrankB.Gilbreth
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1901Schedulingtechniquesforemployees,machines g jobsinmanufacturingHenryL.Gantt 1915EconomiclotsizesforinventorycontrolF.W. Harris H i 1927Humanrelations;theHawthornestudiesElton Mayo 1931Statisticalinferenceappliedtoproductquality: q qualitycontrolchartsW.A.Shewart y

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1935Statisticalsamplingappliedtoqualitycontrol: g inspectionsamplingplansH.F.Dodge&H.G.Roming 1940OperationsresearchapplicationsinWorldWarII P.M.Blackerandothers. P M Bl k d h 1946DigitalcomputerJohnMauchlly andJ.P.Eckert 1947LinearprogrammingG.B.Dantzig,Williams& Li i G B D t i Willi & others 1950Mathematicalprogramming,on linearand 1950Mathematicalprogramming onlinearand stochasticA.Charnes,W.W.Cooper

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1951Commercialdigitalcomputer:largescale computationsavailable.SperryUnivac l bl 1960Organizationalbehavior:continuedstudyof peopleatworkL.Cummings,L.Porter peopleatworkL Cummings L Porter 1970Integratingoperationsintooverallstrategyand policy,W.SkinnerJ.Orlickyand Computerapplicationstomanufacturing,Scheduling G.Wrightandcontrol,Materialrequirementplanning (MRP) 1980QualityandproductivityapplicationsfromJapan: W.E.Demingandrobotics,CADCAMJ.Juran.
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Intermittent Jobbing/JobManufacturing, J g/J g, BatchProduction ContinuousProduction Mass&Flow

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Job shop production are characterized by manufacturing of one or few quantity of products designed and produced as per the specification of customers within prefixed time and cost cost. The distinguishing feature of this is low volume and high variety of products. A job shop comprises of general purpose machines arranged into different departments. Each job demands unique technological requirements, demands processing on machines in a certain sequence.
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Limited products and low volume. Use of general purpose machines and facilities. Highly skilled operators who can take up each job as a challenge because of uniqueness. Large inventory of materials, tools, parts. Detailed planning is essential for sequencing the requirements of each product, capacities for each work centre and order priorities

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1.Operators will become more skilled and p competent, as each job gives them learning opportunities. 2. Full potential of operators can be utilized. 3.Opportunity exists for creative methods and innovative ideas.

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Higher cost due to frequent set up changes. g q p g 2.Higher level of inventory at all levels and hence higher inventory cost cost. 3. Production planning is complicated. 4. L Larger space requirements. i t

1.

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Batch production is defined by American Production and Inventory Control Society (APICS) as a form of manufacturing in which the job passes through the functional departments in lots or batches and each lot may have a different routing. It is characterized by the manufacture of limited number of products produced f p p at regular intervals and stocked awaiting sales.

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Batch production system is used under the following g circumstances: When there is shorter production runs. When plant and machinery are flexible. When plant and machinery set up is used for the production of it d ti f item i a b t h and change of set up i in batch d h f t is required for processing the next batch. When manufacturing lead time and cost are lower as compared to job order production.

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Betterutilizationofplantandmachinery. Promotesfunctionalspecialization. Costperunitislowerascomparedtojoborder production. Lowerinvestmentinplantandmachinery. Flexibilitytoaccommodateandprocessnumberof products. Jobsatisfactionexistsforoperators. Jobsatisfactionexistsforoperators

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Material handling is complex because of g p irregular and longer flows. Production planning and control is complex. Work in process inventory is higher compared to continuous production. Higher t Hi h set up costs d t f t due to frequent changes t h in set up.
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Manufacture of discrete parts or assemblies using a p g continuous process are called mass production. This production system is justified by very large volume of production. The machines are arranged in a line or product layout. Product and process standardization exists and all outputs f ll the same path. ll follow h h

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Standardization of product and process sequence. Dedicated special purpose machines having higher production capacities and output rates. Large volume of products. Shorter cycle time of production. Lower in process inventory. Perfectly balanced production lines. Flow of materials, components and parts is continuous and without any back tracking. Production planning and control is easy. Material handling can be completely automatic.
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Higherrateofproductionwithreduced g p cycletime. Highercapacityutilizationduetoline balancing. Lessskilledoperatorsarerequired. Lessskilledoperatorsarerequired Lowprocessinventory. Manufacturingcostperunitislow. f l

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Breakdownofonemachinewillstopanentire productionline. Linelayoutneedsmajorchangewiththechangesin theproductdesign. h d d i Highinvestmentinproductionfacilities. Thecycletimeisdeterminedbytheslowestoperation. Th l ti i d t i db th l t ti

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Production facilities are arranged as per the sequence g of production operations from the first operations to the finished product. The items are made to fl Th i d flow through the sequence of h h h f operations through material handling devices such as conveyors, transfer devices, etc.

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Dedicated plant and equipment with zero flexibility. Material handling is fully automated. Process follows a predetermined sequence of operations. Component materials cannot be readily identified with fi l product. ith final d t Planning and scheduling is a routine action.

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Standardizationofproductandprocesssequence. Higherrateofproductionwithreducedcycletime. Highercapacityutilizationduetolinebalancing. Manpowerisnotrequiredformaterialhandlingasitis completelyautomatic. Personwithlimitedskillscanbeusedonthe productionline. Unitcostislowerduetohighvolumeofproduction. Unitcostislowerduetohighvolumeofproduction

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Flexibilitytoaccommodateandprocessnumberof y p productsdoesnotexist. Veryhighinvestmentforsettingflowlines. Productdifferentiationislimited.

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Straightlinetype g y Ushapedtype Circulartype Oddangletype

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MexicoCityLPGDepot y p

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Rapidindustrializationwithitscomplexitiesin manufacturingprocessandlayout; Expansionormodificationsinexistingfactories; Settingupofnewindustriesinvolvinghazardsnot knownearlier; Lackofsafetyconsciousnessonthepartofboth L k f f t i th t fb th workersandmanagement; Inadequaterealizationofthefinancialimplicationsof accidents.

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FencingofMachinery WorkonornearMachineryinMotion EmploymentofYoungPersonsonDangerous Machines StrikingGearandDevicesforcuttingoffPower CasingofNewMachinery ProhibitionofEmploymentofWomenand ChildrennearCottonopeners HoistsandLifts LiftingMachines,Chains,Ropes.
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Floors,Stairs,andMeansofAccess Pits,Sumps,openingsinfloor ExcessiveWeights ProtectionofEyes PrecautionsagainstDangerousFumesanduseof PortableLight ExplosiveorInflammableDust,Gas Precautionsincaseoffire P i i ffi SafetyofBuildingandMachinery
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1.MaterialHandling
Wheneverpossible,requiringtheuseand Wh ibl i i h d maintenanceofliftaidequipmentsuchashoists, cranes,forklifts,trolleys,cartsandothermechanical cranes forklifts trolleys cartsandothermechanical devicesratherthanmanuallylifting. Whenmaterialsmustbeliftedbyhand,workers y shouldberequiredtoemployproperliftingtechniques

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2. 2 PersonalProtective Equipment
1.EyeandFaceProtection 2.RespiratoryProtection 3.HeadProtection 4.FootProtection 5.ElectricalProtectiveEquipment 6.HandProtection
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3. GoodHousekeeping
MachineryandStationaryEquipment,Toolsand MachineryandStationaryEquipment Toolsand MovableEquipment,Floors,AislesandPassageways, DoorsandWindows,LoadingDocks,Vents,Grounds, Stairways,Elevators,Storage

4 4.SafeguardingandLockout g g
Lockoutdevices,Training

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5.EffectiveSupervision
safeworkenvironment,writtenmanagement g commitment,medicalprovidertoassistinjured employees,safetycommittees,regularhealthand safetymeetings, safetymeetings

6.MachineSafety/Equipment Handling
communicatemachinesafetyand y equipmentusageprocedures

7.SafetySigns,Boards,Displays 7 SafetySigns,Boards,Displays
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General
depletionofnaturalresources destructionofhabitats

Water
pH oxygenlevel toxicity

Air
airtoxicity smog globalWarming ozoneDepleti
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LandPollution,NoisePollution,Thermal Pollution,VisualPollution Greenhouseeffect,Ozonedepletion,acidification, smogformation,humanhealth,ecosystemhealth. f i h h l h h l h

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GreenManufacturing:
FocalAreas:EnergyConsumption,Water Consumption,HazardousSubstances,Waste Consumption HazardousSubstances Waste Reduction(HazardousandnonhazardousWaste), EmissionReduction(Lead,solvents,decomposition products),MassBalance,Manufacture.

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PrepareachartforTypesof ManufacturingSystems. PrepareachartforTypesofPlant P h tf T fPl t Layoutusedincarmanufacturing,Soft Drinksplant,milkprocessingunit, Bakeryunit,Shipbuilding,Dam y p g constructionetc.

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